Intermediate moisture bar using a dairy-based binder

ABSTRACT

A chewy and intermediate moisture bar is provided that uses a dairy-based binder generally without the need to employ gums, humectants, and sugar syrups as a binder to achieve the moist and chewy texture. In one aspect, the bar includes a dry base uniformly blended with a dairy-based binder that uses high levels of dairy proteins as the main binding component. A method of forming the chewy and intermediate moisture bar is also provided that may use a lay or delay period to allow moisture equilibration or migration from the binder to the dry base.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.12/755,828, filed Apr. 7, 2010 Now pending, which is hereby incorporatedherein by reference in its entirety.

FIELD

The field relates to snack and cereal bars and, in particular, to snackand cereal bars having dairy components as a binder to form a moist,creamy, and chewy bar.

BACKGROUND

Snack and cereal bars are becoming more popular with consumers for theirease in providing a convenient and ready-to-eat product. Common snackand cereal bars typically tend to be either crunchy or chewy. Thecrunchy bars generally have a low water activity less than about 0.5and, in some cases, around 0.2 to about 0.3. Chewy bars generally have ahigher water activity typically greater than about 0.5 and, in manycases, between about 0.5 to about 0.65. Such chewy bars can, in someinstances, be more desired because they resemble the texture andmouthfeel of candy bars. To achieve this chewy texture, such bars mayuse high levels of a binder component relative to the other baringredients, where the binder component helps provide a moist and chewytexture while at the same time holds the various bar ingredients, suchas granola, grains, fruit, nuts and the like together in a cohesive barshape. The binder component acts as a glue to retain the bar in thedesired shape. To achieve the chewy texture, however, many prior snackand cereal bars, similar to many candy bars, use relatively high amountsof sugar syrups, humectants, gums, glycerin, and/or other sugar basedbinding ingredients as one of the main components of the binder. Thesugar syrups, such as corn syrup, isomalt, maltitol, maltose syrups, andthe like, can be useful for forming a moist and chewy bar due to ahumectant effect of these syrups, which tends to retain moisture in thebar. However, such sugar syrups, gums, humectants, and/or glycerin aregenerally less desired in foods for a number of reasons.

Without such binder ingredients in a bar to provide the humectanteffect, simply increasing the moisture level or water content of thebinder in order to increase the bar's chewiness or moistness can rendermanufacturing of the snack or cereal bar difficult on conventional barprocessing equipment. Moreover, high moisture binders without thesetraditional binding ingredients may completely fail to form aself-supporting bar because the binder cannot retain the bar in adesired shape. Conventional bar making equipment commonly includescompression rollers to sheet out a slab of dough, slitting knives to cutthe sheeted dough into a desired width, and guillotine blades to cut theslit dough into a desired length. By increasing the moisture level of abinder without the use of syrups, gums, humectants, or other sugar basedbinders, the higher moisture binder often cannot effectively retain asufficiently firm slab for processing on such equipment. In otherinstances, the increased moisture dough may be too sticky on its outersurfaces, which may cause problems when the bar is processed through thecompression rollers, slitter knives, and guillotine blades because thebar dough may ball-up or pick-off onto the equipment.

Attempts have also been made to employ alternative binders, such asdairy-based binding components, but prior dairy-based binders haveshortcomings that render the dairy binders less than desirable for anumber of reasons. For example, prior snack bars with dairy-basedbinders generally have a lower moisture level resulting in a crispytexture, employ humectants or sugar syrups to maintain higher moisturelevels, add gums to achieve sufficient binding capacity, and/or requirehigh processing temperatures to functionalize the dairy proteins into aneffective binder component. These all tend to be shortcomings of adairy-based binder. As mentioned above, crispy bars generally do notprovide the mouthfeel and eating satisfaction that chewy bars canprovide. While high levels of humectants, sugar syrups, and/or gums maybe effective in forming a self-supporting, chewy bar with dairy-basedbinders, as discussed above, these ingredients are generally lessdesired in foods. High processing temperatures, which are believed to beneeded to functionalize a dairy ingredient into an effective binder, canhave negative organoleptic effects on the dairy components resulting inundesired organoleptic changes such as a cooked flavor, burnt notes,agglomeration, and/or a gritty texture of the finished bar. Cooked orburnt flavor notes takes away from the fresh dairy impression uponeating.

When using large amounts of a dairy source as a binder, it is generallybelieved that heating or cooking the dairy ingredients at temperaturesof at least about 70° C. (158° F.) or higher may be needed in order tofunctionalize the dairy proteins as a binder component. While notwishing to be limited by theory, it is generally believed that heatingdairy proteins helps solublize or disperse casein proteins into anaqueous phase, which then results in an increase in viscosity of thebinder and a much firmer bar. It is generally believed that thesolublized dairy proteins can more easily mix with various additives andform bonds on a molecular level to help bind various materials together.

However, as mentioned above, heating at such high temperatures needed tofunctionalize the dairy is generally undesired. For example, heating adairy-based binder to about 70° C. (158° F.) or above generally causesthe lactose in the dairy binder to be solubilized. Upon cooling of thebar, it is believed that the lactose may solidify into crystals that canform into relatively large agglomerates upon cooling. Such largecrystals or agglomerates may result in a gritty mouthfeel or a bar thatdoes not have texturally smooth or creamy characteristics.

Prior cereal bars employing a dairy-based binder also incorporated gums,humectants, hydrocolloids, glycerin, and sugar syrups in order toachieve a chewy or creamy mouthfeel. Use of large amounts of theseingredients is also generally undesired. These ingredients can be highin sugar and calories and/or impart undesired sweetness and otherunwanted organoleptic characteristics to the bar.

Also, exposing dairy ingredients to high temperatures above about 70° C.(158° F.) also may result in an off-white color to the dairy componentsdue to discoloration of the dairy components in the binder due to theheating. For example, dairy proteins typically undergo browningreactions upon exposure to elevated temperatures. Heating dairy proteinsmay result in color changes and/or gelation during processing orextended storage. It is believed that the lactose in milk, which hasbeen heated to high temperatures, tends to interact with proteins andresults in an unsightly brown color. This undesired condition is oftenreferred to as “browning” or a “browning reaction.” Both gelation andbrowning are undesirable in milk and products using dairy proteins sincethey impart objectionable organoleptic properties and negatively affectthe creamy and white color desired in food bars employing dairycomponents

SUMMARY

A chewy and intermediate moisture bar is provided that uses adairy-based binder generally without the need to employ gums,humectants, and sugar syrups as a binder to achieve the moist and chewytexture. In one aspect, the bar includes a dry base uniformly blendedwith a dairy-based binder, which uses high levels of dairy proteins(such as casein) as the main binding component rather than significantamounts of gums, humectants, and sugar syrups. By one approach, the drybase may be selected from grains, nuts, granola, oats, and the like aswell as mixtures thereof. By one approach, the dairy-based bindergenerally includes about 3 to about 14 percent dairy protein such ascasein, and about 16 to about 35 percent water. Preferably, the binderincludes less than about 0.1 percent non-dairy binding ingredients suchas gums, sugar syrups, humectants and the like. Even without thetraditional binding ingredients of gums, sugar syrups, and humectants,the dairy-based binder effectively functions as a binding component evenwith higher moisture levels and intermediate water activities. To thisend, the dairy-based binder functions as an effective binder, by oneapproach, by employing a dairy protein to moisture ratio of less thanabout 0.5 such that the dairy-based binder includes about 2 to about 5times as much moisture as dairy protein. This ratio is effective inhydrating the dairy protein, but also forming a binder sufficient toform a self-supporting bar shape.

Not only does the binder have high levels of dairy proteins, but thefinal bar also includes a high level of dairy proteins. By one approach,the final bar includes about 3 to about 9 percent total dairy proteinsuch as casein and about 10 to about 40 percent total water to form achewy and moist bar that exhibits fresh dairy notes. The final bar alsohas a total dairy protein to total moisture ratio of less than 0.5 suchthat the bar includes about 2 to about 5 times as much total moisture astotal dairy protein so that the dairy protein is sufficiently hydratedeffective to function as a binder to form the dry base into a moist andchewy self-supporting bar shape at room temperature. Thus, by oneapproach, both the dairy based binder and the final bar havesubstantially the same ranges of dairy protein to moisture levels and,preferably, substantially the same dairy protein to moisture levels,which has been discovered as being effective to functionalize the dairycomponents into a binder when not using substantial amounts of gums,humectants, and sugar syrups. Such composition provides a unique bartexture and eating experience that has not been provided previously.

In addition to the effective ratios of moisture and dairy proteinsdiscussed above, the dairy-based binder and the assembled bar all havecarefully controlled temperature exposures during processing. Forexample and by one approach, a maximum temperature exposure of thedairy-based binder and assembled bar is about 68° C. (155° F.) or lower,and in other approaches, about 43° C. (110° F.) or lower. The carefulcontrol of maximum temperature exposure combined with the ratios ofdairy protein and moisture provides for a bar with less firmness andgreater creaminess than a bar with a higher heat treated binder. Thebars herein provide sufficient protein to hold the bar together, but atthe same time provide for a unique creamy texture that is easy to bitethrough and chew.

In another aspect, a method of forming a chewy and intermediate moisturebar using dairy-based binder ingredients is provided. By one approach,the method prepares a dairy-based binder by blending dairy protein withwater at a temperature of about 68° C. (155° F.) or lower so that thedairy-based binder has a dairy protein to water ratio of about 0.5 orless with about 2 to about 5 times as much water as dairy protein. Thedairy-based binder is then combined with a dry base selected fromgrains, nuts, granola, oats, and the like as well as mixtures thereof toform an intermediate blend wherein both the dry base and theintermediate blend are exposed to a maximum temperature of about 68° C.(155° F.) or lower.

After blending, the intermediate blend is then optionally held for about15 minutes to about 6 hours at about 54° C. (130° F.) or lower tosubstantially maintain the intermediate blend's moisture level and tohydrate the dry base using water in the dairy-based binder such that atotal moisture level of the intermediate blend after the holding periodis within about 5 percent to about 1 percent of a total moisture levelof the intermediate blend prior to the holding period. That is, theintermediate blend neither gains nor loses a substantial amount of waterduring the holding period. After this holding period, the intermediateblend with the retained moisture is then assembled into the chewy andintermediate moisture bar at temperatures of about 68° C. (155° F.) orlower so that the final bar has a total dairy protein to total waterratio of about 0.5 or less with about 2 to about 5 times as much waterthan dairy protein to form a self-supporting bar at room temperature.

DETAILED DESCRIPTION

A moist and chewy ready-to-eat snack or cereal bar is provided. In oneaspect, the ready-to-eat snack or cereal bars include a dairy-basedbinder component and a dry base. The dairy-based binder componentemploys a particular combination of dairy proteins relative to amoisture level to functionalize the dairy proteins as a binder. Thedairy-based binder and combination of dairy protein relative to moistureis effective to form a self-supporting bar without the need to usesignificant amounts of non-dairy binders such as sugar syrups, gums,humectants, and the like. With the dairy protein and moisture levelsused in the dairy-based binder component, it not only renders the snackbar nutritious, but exhibits a moist, chewy, and creamy texture in aself-supporting form even without the syrups, gums, and humectants ofthe prior bars. Instead of relying on syrups, gums, and humectants as abinder component, it has been discovered, in one approach, that theparticular ratios of the dairy protein to moisture in both the binderand the final bar are effective to functionalize the dairy proteins intoa binder sufficient to form a self-supporting bar.

In another aspect, it also has been discovered that particular dairyprocessing conditions combined with the dairy protein and moisturelevels may be effective to facilitate the formation of the moist andcreamy bar when employing such high levels of dairy-based bindingcomponents and moisture in a binder without the use of syrups, gums, andhumectants. In this aspect, with the high dairy and moisture levels inthe binder formula, it is preferred that the binder as well as theassembled bar itself are not exposed to temperatures above about 68° C.(155° F.) and, in some cases, not above about 43° C. (110° F.) duringany processing step. While not wishing to be limited by theory, it isbelieved that by not exposing the dairy-based binder components totemperatures above about 68° C. (155° F.), hydration and/or dissolvingthe lactose is generally avoided at the concentrations of the formulasherein, which may limit the formation of agglomerates or large crystalsof lactose upon cooling; thus, resulting in a smoother and creamiertexture. In addition, maintaining the temperature exposure of the barand bar ingredients below about 68° C. (155° F.) tends to reduce and,preferably, eliminate any protein denaturation and also reduces and,preferably, avoids the formation of cooked or burnt notes. Rather thanheating the dairy components to functionalize them as a binder, as donein prior bars, the dairy-based binders herein use the unique combinationof dairy protein levels relative to certain moisture levels so thateffective dairy protein to moisture ratios are achieved to sufficientlyhydrate the dairy proteins to functionalize them as a binder without theneed for high processing temperatures.

With such increased dairy and moisture levels in the binder, the desiredchewy and creamy texture may also be achieved, in yet another approach,by employing a dough rest or lay period during processing in which thedough is maintained, in one approach, in a relatively large mass withrelatively little surface area effective to allow hydration of thebinder and other components. This rest or lay period is a significantdelay time between blending of the bar and binder components and asubsequent processing into a bar shape. It is believed that this layperiod is effective to allow a portion of the moisture in bindercomponents to hydrate not only the dairy proteins such as caseinproteins, but it is also believed the lay period allows the moisture toequilibrate with any remaining components of the bar, such as the drybase components. Thus, with this approach, the higher moisture used inthe binder is equilibrated between the hydration of the dairy proteinsand remainder of the bar. The lay period enables the formed dough to beprocessed on conventional bar forming technologies. Without the layperiod, the dough is generally too wet and sticky to be easily processedon conventional bar forming equipment. Thus, the snack bars herein mayemploy unique combinations of dairy-based binders, dairy or caseinprotein levels, moisture, and/or processing conditions to form moist andchewy bars without the use of significant amounts of sugar syrup, gums,and humectants as commonly used in prior art bars.

Turning to more of the specifics, the snack and cereal bars providedherein include relatively high amounts of a dairy-based binder componentand, thus, high amounts of dairy proteins, such as casein proteinsrelative to the dry base. By one approach, for example, the final snackbar has at least about 40 percent and, preferably, about 50 to about 60percent of the dairy-based binder component. In this approach, thedairy-based binder component includes particular amounts of dairy orcasein proteins relative to increased moisture levels to ensure that itcan effectively function as a binder without heating and without the useof significant amounts of sugar syrups, gums, and humectants.

As used herein, significant amounts of sugar syrups, gums, and/orhumectants, which may be referred to herein as non-dairy bindingingredients, generally means less than about 0.1 percent, preferably,less than about 0.01 percent, and most preferably, no sugar syrups,gums, and/or humectants. As used herein, humectants include, but are notlimited to, glycerin, sorbitol, mannitol, propylene glycol, butyleneglycol, maltitol, and the like; gums include, but are not limited to,carrageenan, guar gum, locust bean, gum Arabic, xanthan, pectin,gelatin, carboxymethylcellulose, and the like; and sugar syrups include,but are not limited to, corn syrup, isomalt, maltitol, maltose syrups,and the like.

By one approach, the dairy-based binder component includes about 65 toabout 75 percent solids, about 3 to about 14 percent dairy protein(preferably, about 8 to about 14 percent) that is predominately caseinprotein, about 12 to about 20 percent lactose, about 6 to about 25percent fat, and about 16 to about 35 percent water (preferably, about25 to about 35 percent water). The binder also preferably has less thanabout 40 percent non-dairy sugars and, preferably about 8 to about 16percent non-dairy sugars. Even with a binder with such levels ofprotein, lactose, and water without the traditional non-dairy bindingcomponents of sugar syrups, gums, and humectants, the dairy-based bindercomponent is still effective to form a self-supporting bar bymaintaining effective ratios of dairy protein to moisture in both thebinder component and the final bar.

In one embodiment, the binder, as well as the final bar, have a ratio ofdairy protein to moisture less than about 0.5, preferably, about 0.2 toabout 0.5 and, most preferably, about 0.3 to about 0.5 so that thebinder has about 2 to about 5 times (preferably about 2 to about 3times) more water than dairy protein. Such ratios are effective tohydrate the high levels of dairy proteins into a form that can functionas a binder even when maintaining the binder and bar at temperaturesbelow about 68° C. (155° F.) and, in some cases, below about 43° C.(110° F.). Dairy and moisture levels outside these ranges when usingtemperatures below about 68° C. (155° F.) either are too runny tofunction as a binder or too thick to form a creamy bar.

In one form, the protein in the dairy-based binder component may beobtained from aqueous dairy components, dry dairy components, and blendsthereof. For example, the aqueous dairy component may be liquid dairysources, moist or semi-solid dairy sources, and mixtures thereof. Thedry dairy component may be obtained from various dairy powders havinglittle or no moisture (i.e., generally less than about 5 percentmoisture). For example, the dairy-based binder can be formed from blendsof water and dairy ingredients from one or more of the aqueous and/ordry dairy sources in amounts to achieve the desired levels of moisture,solids, protein, and lactose described above.

By one approach, suitable aqueous dairy components for the binderinclude milk (such as skim, reduced fat, 2 percent, whole) cream,condensed milk, sweetened condensed milk, condensed fat-free milk,sweetened condensed fat-free milk, ultrafiltered milk, ultrafilteredcondensed milk, yogurt, other cultured dairy products, and the like.Suitable solid or semi-solid dairy ingredients include yogurts, othercultured dairy products, dairy pastes, cheeses (such as cream cheese,cottage cheese, ricotta, Cheddar, Neufchatel, processed, and the like)and the like. Suitable powdered dairy ingredients include milk powders,cultured powders, non-fat dry milk powders, skim milk powders, milkprotein concentrate powders, whey protein concentrate powders, and thelike.

Preferably, the ratio of dairy protein to moisture forms a bindercomponent that has a paste-like composition, but at the same timesufficient moisture relative to the dairy proteins effective so that thedairy proteins can adequately hydrate without heating to functionalizethe mass as an effective binder. In one approach, the binder has anintermediate water activity of about 0.5 to about 0.9, in anotherapproach, about 0.7 to about 0.9, and yet another approach about 0.7 toabout 0.85. For example, a dairy-based binder component may have a totalmoisture content of about 16 to about 35 percent, and may include blendsof about 19 to about 44 percent of an aqueous dairy source (such asmilk, cream, or cream cheese) and about 8 to about 37 percent dry dairysource (such as non-fat dry milk powder) with less than about 40 percentnon-dairy sugar. As further discussed below, if the water activity andmoisture level is higher or lower, the dairy based binder will notfunction without the use of high heat levels and/or sugar syrups, gums,and humectants.

The dairy-based binder component is blended in a substantially uniformmanner with an edible or dry base component. By one approach, the barincludes up to about 60 percent of the edible base component,preferably, about 35 to about 50, and most preferably, about 35 to about45 percent blended with the dairy-based binder component. By oneapproach, the edible or dry base component may include grains, granola,oats, nuts, and the like as well as mixtures thereof. In otherapproaches, the edible or dry base component may also include fruits,cookies, raisins, soy crisps, oatmeal, cereals, cake, cookies, pretzels,pasta, grain based products, starches, rice, wheat, other amylaceousmaterials, and the like, and mixtures thereof. Optionally, the bar mayalso be blended with various inlays or other ingredients as desired,such as various intermediate and high moisture fruits, nuts, raisins,candies, flavors, nutrients, and the like. If such inlays are included,it is preferred that snack and cereal bar includes about 5 to about 8percent of such inlays. If desired, the bar may also be coated orenrobed or have blended therein a coating, such as chocolate, caramel,and the like. Alternatively, the bar may have multiple layers of thebinder, edible base component with various fillings, fruit, and/orcoatings therebetween.

In another aspect, the final snack and cereal bars have intermediatemoisture levels between about 10 and about 40 percent (in anotherapproach, about 10 to about 18 percent), which results in anintermediate water activity of the bar of about 0.5 to about 0.9, insome cases, about 0.7 to about 0.9, and in other cases, about 0.7 toabout 0.85. It is believed that such moisture level relative to thedairy protein levels is effective to lower the viscosity of thedairy-based binder helping to functionalize the dairy components (suchas casein proteins) into an effective binder without the need forexcessive heating, which as mentioned above results in several undesiredproblems when using significant amounts of dairy components. Theresultant bar is moist and creamy, which is tender to chew but does nothave a soggy texture. With the dairy-based binder that is assembled intoa bar without heating, the bars also exhibit enhanced fresh milk anddairy flavors, exhibit enhanced whiteness, and are generally free ofcooked and/or other off-flavors typically found in dairy products whenexposed to high temperatures.

Because the dairy-based binder component and assembled bar, in oneapproach, are not exposed to high temperatures during processing,several optional ingredients not possible in the prior bars can easilybe incorporated into the bar. For instance, because the snack or cerealbars herein are not heated above 43° C. (110° F.) in some approaches,the bar may include live and active cultures. In such approach, the liveor active cultures may be provided by yogurt, other cultured dairyproducts, cheese, probiotics, and mixtures thererof. The live and activecultures may be included in either the dairy-based binder component orthe dry base component.

The dairy-based snack and cereal bars described herein are generallysolid at ambient temperatures (i.e., about 22 to about 25° C.) and havemoisture levels in the finished or assembled bar of about 10 to about 40percent and, in other instances, about 20 to about 40 percent. The barsare moist and chewy, but retain a solid structure, which generallyrefers to the bar and binder system as being sufficiently firm to beself-supporting at ambient temperatures. By being self-supporting, thebar is capable of being picked up and held in a horizontal positionwithout significant deformation or drooping. By another approach, thefirmness of the bar at room temperature may be measured as thepenetration of an unaerated bar that is greater than about 150 gramsforce, preferably about 150 to about 15,000 grams force, and morepreferably about 1,000 to about 10,000 grams force. Firmness can bemeasured using a universal testing machine in the penetration mode(e.g., Texture Technologies TA-XT2 using a 45° conical probe) or similartesting equipment.

The dairy-based binder may also include a number of optional ingredientsdepending on the particular application. For example, the binder mayinclude emulsifiers, emulsifying salts, stabilizers, bulking agents,preservatives, colorants, vegetable or dairy fats, sweeteners, flavors,edible acids, fruits, nuts, nutrients, vitamins, mineral supplements(e.g., calcium fortification), and starches among other ingredients. Forexample, optional binder ingredients may include titanium dioxide (forcolor), potassium sorbate (preservative), maltodextrin (filler), soylecithin (emulsifier), wheat dextrin (filler), soy fiber (fiber source),anhydrous milk fat (creaminess), salt, starches, and lactic acid.Suitable optional emulsifying salts may include, for example, sodiumcitrate, potassium citrate, monosodium phosphate, disodium phosphate,trisodium phosphate, sodium aluminum phosphate, sodium tripolyphosphate,sodium hexametaphosphate, dipotassium phosphate, sodium acidpryrophosphate, and the like, as well as mixtures thereof. If used,sodium citrate, disodium phosphate, or mixtures thereof are thepreferred optional emulsifying salts. Suitable emulsifiers may alsoinclude, for example, monoglycerides, diglycerides, polysorbates, sodiumstearoyl lactylate, lecithin, and mixtures thereof as well as the like.If used, monoglycerides, diglycerides, sodium stearoyl lactylate, andmixtures thereof are the preferred optional emulsifiers. Preferably,such emulsifiers may be used in aerated solid milk products. Thedairy-based binder may optionally include sweeteners, such asnon-lactose sweeteners. The sweeteners may also be artificialsweeteners. For instance, the binder may include sucrose, dextrose,fructose, glucose, maltose, corn syrup, honey, and non-nutritivesweeteners. If used, the preferred sweetener is sucrose. The addedsugars or sweeteners can be added separately or via sweetened condensedmilk. Preferably, as discussed above, the non-dairy sweetener is lessthan about 40 percent of the binder, and preferably, about 8 to about 16percent.

The dairy based binder may also optionally include added ediblevegetable and dairy fats. Suitable edible fats include, for example,butter, cream, anhydrous milk fat, vegetable fats, coco butter, andmixtures thereof as well as the like. If used, the edible fat maygenerally have a melting point less than about 50° C. In other cases, itmay be desired to use edible fats with a melting point of about 35 toabout 45° C. If used, the edible fat is preferably anhydrous milk fat,and preferably melted prior to incorporation in the binder orbinder/base blend.

If desired, these optional ingredients can be incorporated into thebinder or bar so long as these additives do not interfere or adverselyeffect the desired properties (i.e., firmness, water level, processingrequirements, and the like). If included, these additives generallyconstitute less than about 10 percent of the final product (except thesweetener). Such additives can be added either during the initialblending or after essentially all components have been hydrated.Preferably, solid additives may be added during the shear treatment andliquid additives may be added during the initial blending. Of course, incases where it is desired to maintain the physical integrity of theadditives (e.g., fruit, nut, or grain pieces), the addition maygenerally be completed under low shear conditions.

The dairy-based binder component of the snack and cereal bars may alsobe aerated. In an aerated product, the overrun of the aerateddairy-based binder component and/or final bar may be about 5 to about100 percent and, in some cases, about 15 to about 60 percent. Otheraeration levels may also be used as appropriate. Aerated dairy basedbinders preferably contain about 0.05 to about 0.7 percent emulsifier,and more preferably about 0.15 to about 0.4 percent emulsifier. Forexample, the dairy binder may be aerated using a gas injection such as,for example, air, nitrogen, or carbon dioxide. Other aeration techniquesmay also be used. Generally, the aerated binder may have a density ofless than about 1.14 g/ml as compared to a density of about 1.2 to about1.3 g/ml for the unaerated product. Aeration can be used to preparedairy based binders which resemble ice cream, yogurt, and the like.

Turning now to a method of forming the snack and cereal bar. By oneapproach, the method of forming the dairy-based binder and the final barcarefully controls the maximum temperature exposure of the ingredients.For example, the dairy-based binder components (and in particular thedairy components thereof) as well as the assembled bar occurs attemperatures of about 68° C. (155° F.) or below and, in some cases,about 43° C. (110° F.) or below. That is, the binder, dairy components,and the assembled bar are not exposed to temperatures of about 68° C.(155° F.) or above, and in some cases, not exposed to temperatures above43° C. (110° F.).

To prepare the binder, the various liquid and dry ingredients areblended. First, the dairy-based binder component is prepared by blendingthe dairy protein source(s) with water (if needed) within theappropriate ratios as discussed above. The blend is mixed under highand/or low shear conditions until a homogenous paste is obtained. Duringthe mixing and blending, the temperature is maintained at about 68° C.(155° F.) or below and, optionally, about 43° C. (110° F.) or below.After the homogenous paste is obtained, the dry base component may beadded or mixed into the paste to form an intermediate blend. During thismixing step, the temperature of the intermediate blend is maintained atabout 68° C. (155° F.) or below and, optionally, about 43° C. (110° F.)or below. After these mixing steps, the resultant mixture orintermediate blend may be cooled, such as to below about 40° C. (104°F.) and, in some cases, to below about 10° C. (50° F.) to form a cooledintermediate blend. If desired, the intermediate blend or bindercomponent can be homogenized before cooling.

The intermediate blend may then be formed or assembled into a bar-shapeusing conventional techniques. By one approach, the bar can be sheeted,layered, or extruded. The bar can be molded or cut into the desiredshapes. In other approaches, the intermediate blend can be filled intovarious containers or formed into solid bars, candy-type bars, cookies,cookies or bars with other ingredients (e.g., granola, grains, peanuts,other nuts, chocolate bits or chips, and the like), bite-sized forms orpieces, enrobed solid forms, shapes (e.g., animal, stars, letters), andthe like. The bar can be produced with varying levels of sweetness asneeded.

In another approach, the intermediate blend of the dairy-based bindercomponent and dry base component may optionally be subjected to a delayor lay period prior to any further processing (such as bar formation).This delay period is effective to enable moisture migration and moistureequilibration through the dough binder and dry base. By one approach,the binder components and dry base components may be blended together atabout 68° C. (155° F.) or below (optionally about 43° C. (110° F.) orbelow) for a time effective to form a cohesive dough mass (by oneapproach about 5 to about 10 minutes). The dough mass is then allowed tosit or lay (by one approach, at room temperature (about 20 to about 25°C.) and, in another approach, at temperatures up to about 125 to about130° F.) for about 15 minutes to about 6 hours and, preferably, about 2to about 2.5 hours to allow moisture migration to hydrate the dairyproteins, providing increased strength to the binder, and to allowmoisture equilibration between the hydrated dairy proteins and the drybase component. Providing for this in-process moisture migration enablesa higher moisture bar to be prepared on a variety of process equipmentbecause the binder is strengthened proportionally to the amount ofmoisture migrated to the dry base.

Preferably, the final bar has a moisture loss of about 5 percent or less(preferably, about 1 percent or less) during formation where themoisture of the binder equilibrates and migrates to the dry base ratherthan being evaporated or otherwise lost. By one approach, to achievesuch moisture migration and equilibration, the intermediate blend mayoptionally be retained and/or formed into a relatively large dough masshaving a larger volume than surface area to promote sufficient doughcontact. Such dough mass during the lay period is effective, in oneapproach, to provide adequate volume and intimate contact of the doughfor efficient moisture migration and equilibration. For example and byone approach, the dough mass of the intermediate blend during the layperiod may have a volume to surface area ratio of about 1 in³ per in²(or be held in a container providing such volume to surface area) duringthis lay period to adequately effect moisture migration. By anotherapproach, the delay or lay period may optionally occur in asubstantially sealed environment or substantially sealed container,which effectively minimizes moisture loss from the intermediate doughand/or any moisture uptake from the environment during the lay period.By another approach, the sealed container or environment may optionallyalso have a relative humidity of about 75 percent or lower to helpmaintain the moisture level of the dough. By yet another approach, thesealed container may optionally have such relative humidity levelsmaintained in a relatively small headspace or other area between anexposed surface of the dough and a seal, cover, or other containment ofthe environment or container. By yet another approach, the dry basecomponent may be optionally sprayed with oil, water, or other aqueousliquid prior to being blended with the dairy-based binder to helpfacilitate the moisture uptake from the binder.

Preferably, it is desired that after the lay period, the moisture levelof the dough is within plus or minus about 1 to about 5 percent of themoisture level of the dough prior to the lay period and, preferably,within plus or minus about 1 percent. In other words, the dough does notlose or gain any significant amounts of moisture. It will be appreciatedthat the above described processing conditions of the lay period areonly exemplary and other conditions, equipment, and processingparameters may also be used as needed to achieve the desired moistureequilibration, migration, and retention during processing.

By employing such a delay or lay period to substantially maintainmoisture levels, the finished bar preferably exhibits a total dairyprotein and total moisture levels substantially the same as the dairyprotein and moisture levels of the dairy-based binder because little tono moisture is lost from the product. That is, the finished bar exhibitsa total dairy protein to total moisture level of less than about 0.5and, preferably, about 0.2 to about 0.5, which is within the same rangeas the ratios of the dairy-based binder component. Preferably, the totaldairy protein to total moisture levels of the final bar aresubstantially the same as the ratios of the dairy based binder (forexample, within about 1 to about 5 percent and, preferably within about1 percent or less). While not wishing to be limited by theory, it isbelieved this delay or lay period helps facilitate moisture migrationfrom the binder component to the dry base for ease of processing andformation of an effective binder. Preferably, it is desired that themoisture content of the dough is not significantly affected during thislay period, which is distinct from baking, cooking, and other hightemperature processing operations of the prior art dough and bars, whichcan reduce moisture levels.

Advantages and embodiments of the food and cereal bars described hereinare further illustrated by the following examples; however, theparticular conditions, processing schemes, materials, and amountsthereof recited in these examples, as well as other conditions anddetails, should not be construed to unduly limit this method. Allpercentages are by weight unless otherwise indicated.

EXAMPLES Example 1

A dairy and granola bar was prepared with a dairy-based binder componenthaving about 66 percent solids, about 34 percent moisture, about 8.5percent dairy fat, and about 13.9 percent dairy protein. The binder hasa dairy protein to moisture level of about 0.4. One form of the binderincluded sodium citrate as an emulsifying salt to modify the texture andmouthfeel of the finished bar. These dairy based binders had thecomposition of Table 1 below.

TABLE 1 Dairy Based Binder Ingredient Binder 1A, lbs Binder 1B, lbsCream (42% fat) 19.3 19.3 Water 22.2 22.2 Sugar 16.0 16.0 Non-fat drymilk 37.6 37.6 powder (NFDM) Maltodextrin 4.8 4.3 Sodium Citrate 0 0.5

To prepare the binder, the water and cream were first mixed in a Breddomixer for about 5 minutes at about 7° C. Then, NFDM, maltodextrin,sugar, and optional sodium citrate were then added to the mixer andblended for about 10 minutes after all ingredients were added using lowshear until uniform and smooth. The temperature increased duringblending from about 10° C. to about 39° C.

Next, the dairy based binder component was then combined with granola,raisins, and flavors at about 39° C. The blend included about 50 percentdairy-based binder component, about 42.5 percent granola, and about 7.5percent raisin and flavors. The blend was then processed into bars byslabbing the mixture, compressing the slab, cooling to about 10° C.,cutting into the bar shape, and packaging.

After about 3 days, the bar formed using Binder 1A and 1B had a wateractivity of about 0.8 (measured at 25° C.). The bar with Binder 1Aformed an acceptable chewy bar that had a soft chew, was less dry, andless crumbly than the bar with Binder 1B. However, the bar with Binder1B was also acceptable with a slightly firmer bite and chew.

Example 2

Another dairy and granola bar was prepared using small amounts of anoptional stabilizer to modify the binder texture to create differencesin eating quality. In this Example, the dairy based binder was about 70percent solids, about 30 percent moisture, about 8.5 percent fat, andabout 13.9 percent dairy protein. The binder had a dairy protein tomoisture level of about 0.46. The binder has the composition of Table 2below.

TABLE 2 Dairy-Based Binder Ingredients Amount, lbs Cream (42% fat) 19.6Water 17.6 Sugar 16.0 Sodium Citrate 0.5 NFDM 37.7 Maltodextrin 8.5 Fatmimetic (sodium alginate) 0.08

To prepare the binder, an alginate slurry was first prepared by mixing 1pound of sugar, 3.5 pounds of water, and the alginate (Sodium Alginate,1000-1500 cps, Kimitsu Algin LZ-2) at 12° C. for about 10 minutes. Thesugar was used to disperse the alginate. Next, water and cream wereblended in a Breddo mixer for about 5 minutes at about 7° C. Then, theNFDM, maltodextrin, remaining sugar, and the pre-hydrated alginateslurry were added to the mixer and blended for about 10 minutes afterall additions until uniform and smooth. The temperature increased fromabout 10° C. to about 39° C.

The formed dairy based binder was then assembled with granola, raisins,flavors at about 39° C. The composition included about 50 percent dairybinder, about 42.5 percent granola, and about 7.5 percent raisins andflavor. The mass was then assembled into bars using the same procedureof Example 1. After about 3 days, the finished bar had a water activityof about 0.75 (measured at 25° C.) and a moisture content of about 16.6percent. The bar formed an acceptable chewy texture and was less stickythan the same bar without sodium alginate.

Example 3

A cream cheese based dairy binder was prepared and assembled into a bar.The binder has the composition of Table 3 below.

TABLE 3 Cream Cheese Based Binder Ingredient % Cream cheese (58%moisture, 29% fat) 43.9 Maltodextrin 8.8 Sucrose 8.3 Sodium Chloride 0.3Skim milk powder 8.8 Wheat dextrin 17.6 Potassium sorbate 0.2 Flavor 0.8Titanium dioxide 0.2 Lactic acid 0.7 Small granular native rice starch10.5

To prepare the binder, the cream cheese is first blended in a Breddomixer under high shear with the maltodextrin and sucrose for about 5minutes, with the temperature increasing to about 15° C. Then the sodiumchloride, milk powder, wheat dextrin, potassium sorbate, flavors,titanium dioxide and lactic acid were added. When sufficiently blended,the rice starch was added and blended under high shear. All of themixing was conducted without adding heat, the temperature eventuallyreached about 43° C. The result is a liquid and pumpable paste.

Separately, about 73.5 parts baked oat granola is blended with about26.2 parts whole oat flakes (previously sprayed with about 15 percentwater on top and baked for 6 minutes at about 390° F. and then cooled toroom temperature), about 0.26 parts fruit or other flavor. Then about56.9 percent of the cream cheese dairy binder was blended with about38.1 percent of the granola/cereal blend and about 5 percentintermediate moisture fruit (Aw of about 0.85) using low shear untiluniformly mixed and coated. The mixture was allowed to rest at roomtemperature (i.e. about 75° F.) for about 3 hours.

The mixture was then pressed into molds and released from the molds. Theproduct attained its final firmness after about 4 days. The wateractivity of the finished bar was about 0.85. The bar had a pH of about5.0.

Example 4

Three separate high-moistness bars with a water activity between about0.7 and about 0.8 that contained at least about 50 percent binder wereprepared. A binder having the ingredients of Table 4 below was used foreach of the bars. This example compared the results of using the laytime during processing. The binder of Table 4 had about 74 percentsolids, about 26 percent moisture, about 20 percent fat, and about 9percent protein. This binder had a dairy protein to moisture ratio ofabout 0.35.

TABLE 4 Binder Ingredients Quantity, Lbs Percentage Cream (42% fat) 77.531.6 Sugar 37.5 15.3 NFDM (high heat) 53.2 21.7 Maltodextrin 25.9 10.6Water 18.4 7.5 Soy lecithin 2.5 1.0 Soy Fiber 2.5 1.0 Frutalose 12.5 5.1Anhydrous Milk Fat 15.0 6.1 Total 245 100

To prepare the dairy based binder, the anhydrous milk fat (AMF) wasfirst warmed to about 125° F. and then mixed with the water and cream ina Breddo mixer at about 125 to about 130° F. Then, the remainder of thedry ingredients were dry blended and then added to the liquid mixture.The liquid soy lecithin was added last. After mixing, the dairy basedbinder was uniform and smooth. The dairy based binder was used toprepare three separate cereal bars: 4A, 4B, and 4-Control. Thecomparative results of these bars are provided below in Table 5.

For the 4-Control bar, the dairy-based binder was blended with granolaand strawberry pieces for about 5 minutes blending time to form a doughmade up of about 50 percent dairy based binder, about 42.5 percentgranola, and about 7.5 percent strawberry pieces. The mixture wasimmediately (within less than about 5 minutes) processed into bars usingconventional bar making equipment by first sheeting the dough,compressing the sheeted dough, using a cooling tunnel, slitting to adesired width, and guillotine cutting to a desired length.

For Inventive Bar 4A, the dairy-based binder was blended with the samegranola and strawberry pieces for about 5 minutes of blending time toform a dough made up of about 50 percent dairy based binder, about 42.5percent granola, and about 7.5 percent strawberry pieces. Afterblending, the dough mixture was allowed to lay or equilibrate in a 5gallon pail at about 125° F. for about 2.5 hours before furtherprocessing. Minimal moisture was lost during this lay period (estimatedat about 5 percent or less). After the lay time, the dough was processedinto Bar 4A using the same conventional bar making equipment as thecontrol.

For inventive Bar 4B, the dairy-based binder was blended with the samegranola and strawberry pieces for about 5 minutes of blending time toform a dough made up of about 55 percent dairy-based binder, about 37.5percent granola, and about 7.5 percent strawberry pieces. Afterblending, the dough was very wet. The wet dough was allowed to lay orequilibrate in a 5 gallon pail at about 125° F. for about 2.5 hoursbefore further processing. Minimal moisture was lost during this layperiod (estimated at about 5 percent or less). After the lay time, thedough was processed into Bar 4B using the same conventional bar makingequipment as the control.

TABLE 5 Results Parameter 4-Control Bar 4A Bar 4B % Binder 50   50 55 %Moisture 12.4 12.4 13.7 % Dairy  3.7 3.7 4.1 Protein % Dairy fat  9.79.7 10.6 Lay time None 2.5 hours at 125° F. 2.5 Hours at 125° F.Observations Loose More cohesive mass, less More cohesive Duringmixture, wet, less binder loss at mass, less Sheeting and significantsheeting and compression free binder Compression binder loss rollerObservations Dry on top Significantly less sticky Bars were firm aftercooling but sticky than the control bar on enough to be tunnel on bottomof both top and the bottom. picked up the bar, soft Bars were firmerthan without control and were firm significant enough to be picked updeformation without deformation Tasting Soft, moist, Soft, more moistthan Very Moist within about chewy control, more cohesive 1 Month chewTasting Soft, chewy, Softer than control, more Very soft and withinabout some cohesive chew than control, moist, uniform 4 Months dryparticles more uniform texture than chew, least control mouth drying

As compared to the control, the lay time made the bar surface lesssticky and increased bar strength per the horizontal hold test duringprocessing. The finished bars 4A were more moist and cohesive in texturethan the control even though the formula was identical to the control.When the binder was increased to about 55 percent of the finished bar,without the lay time, the bars could not be processed using conventionalbar equipment. After the about 2.5 hours of lay time, the 4B bars weresuccessfully produced using conventional equipment.

Example 5

A dairy-based bar was prepared using Philadelphia-brand cream cheese(Kraft Foods, Northfield, Ill.) The dairy-based binder was the formulaof Table 6 below.

TABLE 6 Binder Ingredient % Cream Cheese (29% fat, 42% dry-matter) 43.9Maltodextrin (Avebe Paselli WFR, Avebe 8.7 America, Princeton, N.J)Sugar 8.2 salt 0.3 Skim Milk Powder 8.7 wheat dextrin 17.6 Potassiumsorbate 0.2 Flavors 0.9 TiO2 0.2 Lactic Acid 0.7 small granules/nativeRice starch 10.5

To prepare the dairy-based binder, the cream cheese, maltodextrin, andsugar were blended at room temperature (about 20 to about 25° C.) untilhomogeneous and smooth (approximately about 5 minutes.) Then, theremaining ingredients were added at room temperature to form a pumpablepaste. The paste was then transferred to a bowl or dough kneader wheredry ingredients are mixed in. The dry ingredients are set forth in Table7 below.

TABLE 7 Dry Base Ingredient % Baked Oat Granola 65.0 Baked Whole OatFlakes 23.2 Flavor 0.2 Strawberry (Aw = 0.85) 11.6

The oat flakes were first placed onto a baking plate and sprayed withabout 15 percent water and baked in an oven at about 200° C. for about 6minutes. The dry ingredients of Table 7 were then gently blended withthe dairy binder at room temperature. The mixed dough mass when thenallowed to sit at room temperature while still in the blender for about3 hours. The equilibrated mass was then formed into about 50 gram barsusing a bar mold into which the dough was pressed by hand. The formedbars were then stored chilled for about 4 days. The final bars had about3.3 percent dairy protein, about 16 percent moisture, about 8 percentfat, a water activity of about 0.85, and a pH of 5. The final bars had adairy protein to moisture ratio of about 0.2.

It will be understood that various changes in the details, materials,and arrangements of the process, formulations, and ingredients thereof,which have been herein described and illustrated in order to explain thenature of the method and resulting concentrate, may be made by thoseskilled in the art within the principle and scope of the embodied methodas expressed in the appended claims

What is claimed is:
 1. A chewy and intermediate moisture bar using adairy-based binder, the bar comprising; a dry base selected from one ofgrains, nuts, granola, oats, and mixtures thereof; a dairy-based binderincluding about 3 to about 14 percent dairy protein, about 16 to about35 percent water, and less than about 0.1 percent non-dairy bindingingredients all based on the weight of the dairy-based binder, and adairy protein to moisture ratio of less than about 0.5 such that thedairy-based binder includes about 2 to about 5 times more moisture thandairy protein, the dairy-based binder blended with the dry base; about 3to about 9 percent total dairy protein, about 10 to about 40 percenttotal water, and a total dairy protein to total moisture ratio of lessthan 0.5 such that the bar includes about 2 to about 5 times more totalmoisture than total dairy protein so that the dairy protein issufficiently hydrated effective to function as a binder to form the drybase into a moist and chewy self-supporting bar shape; a maximumtemperature exposure of the dairy-based binder and the chewy andintermediate moisture bar is about 155° F. or lower; and wherein thedairy-based binder includes a blend of an aqueous dairy source and a drydairy protein source.
 2. The chewy and intermediate moisture bar ofclaim 1, wherein the dairy protein to moisture ratio of the binder andthe total dairy protein to total moisture ratio of the chewy andintermediate moisture bar are both about 0.2 to about 0.5.
 3. The chewyand intermediate moisture bar of claim 1, wherein the aqueous dairysource is selected from the group consisting of cheese, cream, milk,yogurt, cultured dairy products, and mixtures thereof.
 4. The chewy andintermediate moisture bar of claim 1, wherein the dry dairy proteinsource is selected from the group consisting of non-fat dry milk, milkpowders, milk protein concentrate, whey protein concentrate, culturedpowders, and mixtures thereof.
 5. The chewy and intermediate moisturebar of claim 1, further comprising about 40 to about 60 percent of thedairy-based binder and about 60 to about 40 percent of the dry base. 6.The chewy and intermediate moisture bar of claim 1 having no non-dairybinding agents.
 7. The chewy and intermediate moisture bar of claim 1,wherein the dry base includes about 30 to about 45 percent grains, nuts,granola, oats, or mixtures thereof and up to about 5 percent of a low orintermediate water activity fruit with a water activity less than about0.5.
 8. The chewy and intermediate moisture bar of claim 1, wherein themaximum exposure temperature of the dairy-based binder and the chewy andintermediate moisture bar is about 110° F. and the dairy-based binderincludes live and active cultures.
 9. The chewy and intermediatemoisture bar of claim 1, wherein the chewy and intermediate moisture barhas a water activity of about 0.5 to about 0.9.
 10. The chewy andintermediate moisture bar of claim 9, wherein the water activity isabout 0.7 to about 0.85.
 11. The chewy and intermediate moisture bar ofclaim 1, wherein the chewy and intermediate moisture bar includes about8 percent to about 16 percent sugar solids.